Stability optimal selection of stock shape and tool axis in finishing of thin-wall parts

Abstract In 5-axis milling of thin-wall parts, flexibility of the in-process-workpiece (IPW) governs static and dynamic deflections. Thus, the stock shape left around the part and the tool axis are crucial for stability. This paper presents a methodology for selection of stock shape and tool axis for improved stability. Constant stock finishing is compared to variable stock, where a novel tool path generation approach is used to achieve the desired semi-finish shape. Effect of stock shape on IPW structure is simulated in FEM and benefits are shown. The proposed method is experimentally verified on case studies.

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